Pneumatic mattress



March 28, 1944. G. H. PERRY PNEUMATIC MATTRESS Filed May 3, 1941 2Sheets-Sheet l 35 J4 a6 3P a4 FIELEI.

' G. H. PERRY PNEUMATIC MATTRESS March 28, 1944.

Filed May 3, 1941 2 Sheets-Sheet 2 FIEJE- QJ PaTVJ m L m W. m. F

INVENTOR.. SsaaE/-A FERRY BY E l 6 H TTORMYS Patented Mar. 28, 19442,345,421 PNEUMATIC MATTRESS George H. Perry, Brooklyn, N. Y., tressCorporation of America,

New York assigner to Aira corporation of Application May 3, 1941, SerialNo. 391,697 7 Claims. (Cl. 5-348) This invention relates to improvementsin pneumatic mattresses and the like, and has for ay principa1 objectthe provision of @mattress having the upper and lowersheetsspiliiidtogether to form tufts, and in which'the points at whichsaid sheets are secured together are perforated, whereby ventilationtherethrough is inherently provided when the mattress is in use.

Another object of the invention is the provision of a mattress or thelike of improved comfort, flexibility, form-fitting ability, durable inconstruction, and more easily manufactured.

A further object of the invention is the provision in a pneumaticmattress or the like of a simple and inexpensive way of securing theupper and lower sheets of material together to form tufts. This is donewithout the addition d! extra material exceptv in cases where it isdesired to reinforce the points where the sheets are secured together.

Yet another object of the invention is the provision'of a pneumaticmattress adapted to yield elastically under the weight of a user withoutabrupt snubbing and having a minimumv tendency to curl and roll.

A still further object of the invention is the provision of a pneumaticmattress having an entrance and an exit for air, and means for drawingthe air from said mattress, passing it through a medium for changing itsheat content and returning it to said mattress continuously.

Another object of the inventionv is the provision of a pneumaticmattress having a section therein which may be inflated or deilatedindependently of the main body of the mattress.

' 'Ihis form of mattress is particularly adapted for hospital orsick-room use as the separately deatable section may be deflated topermit the placing of a bed-pan or the like in position with a minimumof discomfort and a minimum of movement of the patient.

A still further object of the invention is the provision of a mattresshaving independently and selectively inflatable and deiiatablevariations whereby the depth of such sections or the contour of theentire surface of the mattress as a wholemay -be changed in accordancewith the use for which the mattress is to be put.

A further object of the invention is the provision of a pneumaticmattress or the like having a casing formed of ticking removablypositioned thereon, said mattress including removable and replaceablepadding between the rubber body and said outer casing. This type ofmattress is very useful due to the fact that should the Dads beprangement shown in come matted or soiled, they may be removed andreplaced with fresh ones.

Other objects of the invention will be obvious to those skilled in theart as this speciiication is read.

Referring to the drawings which illustrate embodiments of the inventionand modifications thereof suflicient to illustrate the invention- Figure1 is a plan view of a mattress forming one embodiment of the inventionand having a portion of the outer casing and a portion of gie paddingbroken away to show the construcon;

Figure 2 is a sectional elevation of the mattress as viewed along thelines 2-2 of Figure 1;

Figure 3 is a sectional elevation of the pneu matic portion of themattress deflated, the casing and padding having been removed;

Figure 4 is a sectional elevation of the mattress as seen along thelines 4-4 of Figure 2 showing the form taken by the mattress when it issubjected to the weight of a body;

Figure 5 is a sectional elevation showing an upper sheet superimposed ona lower sheet with the holes therein concentric;

Figure 6 is a sectional view showing the ar- Figure 5 after the edgesbordering the hole of the lower sheet have been pulled through the holein the upper sheet and adhered to the latter;

Figure 'I is a view showing an upper sheet superimposed on a lowersheet, and a reinforcing ring positioned on the upper sheet, the holesin all of the members being concentric;

Figure 8 is a sectional view showing the arrangement shown in Figure 7after the edges bordering the holes of the lower sheet have been pulledthrough the hole in the upper sheet and the reinforcing ring, andadhered to the latter and the upper sheet about said reinforcing ring;

Figure 9 is a fragmentary view showing the reinforced joint of Figure 8when the mattress is inflated;

Figure 10 is a fragmentary exploded view showing the members in Figure 1before they are placed together;

Figure 11 is a fragmentary view showing a joint such as is shown inFigure 6 after the latter has been inflated, a reinforcing grommethaving been superimposed over the joint for reinforcing the same Figure12 is a perspective view tress formed with a pneumatic and lowersurfaces of showing a matbody, the upper which are covered with aremovable pad, said body and said pad being positioned within a casingwhich is zipped open so that the interior may be seen;

Figure 13 is an elevation, partly in section, of a modification in whichthe mattress is formed of a plurality of units. each being independentlyinflated and deflated;

Figure 14 is a perspective view of the middle section showing strapsattached tothe casing so that the latter may be secured to a support;

Figure 15 is an exploded view showing the pneumatic body of the sectionshown in Figure 14, the upper and lower removable pads, :and the coveror casing with a zipper-type opening;

Figure 16 is a cross sectional view of the section shown in Figures 14and 15 and the shape it assumes when the weight of a body is imposedthereon;

Figure 17 is a view showing how the sections of the arrangement shown inFigure 13 may be inated to different heights for certain types oftreatment;

Figure 18 is a fragmentary view showing a modified form of the pneumaticsection of the mattress shown in Figure 1; and

Figure 19 is a fragmentary view showing a further modification of thepneumatic section of the mattress shown in Figure 1.

After the pneumatic mattress cushion has been made, the at surfaces aresubstantially the same and it makes no difference which one isuppermost.

In Figure 3, the cushion is actually upside down with respect to theposition it was in when being constructed. Figures 5 and 6 show thesteps taken in securing the sheets together, and it will be noted that asheet 30 is superimposed on a sheet 3| of rubber or the like, which atthis stage is uncured.

The sheet 30 has a plurality of holes formed therein, such as the hole32 shown in Figure 5, and the sheet 3| has a plurality of holes 33formed therein. The holes are so positioned that when the sheets arepositioned together with corresponding holes in alignment, they assumerelative positions such as that shown in Figure 5.

The material about the edges of the hole 33, designated by the numeral34, is pulled through the hole 32 and adhered to the surface of thesheet 30 about the hole 32, as shown in dot-dash lines in Figure 5, oras shown in solid lines in Figure 6. The sheets of material are formedof rubber in the uncured state, and as received from the suppliers, theyhave their surfaces treated with a powder to prevent them from stickingtogether. After the holes are formed therein and the sheets arepositioned as described, the operator cleans the surfaces of sheet 30 inzones adjacent to the edges of the holes 32 with gasoline, benzine, orthe like. This removes the powder and all dirt and grease therefrom sothat the pulled throug edges of the holes 33 readily adhere to saidcleaned surfaces. When the sheets are joined in this manner through allof the holes formed therein, and the edges 35 of the sheets are securedtogether and the entire cushion is vulcanized, an air-tight bag isformed.

Joints constructed in the manner shown in Figures 5 and 6 may be termedannular selfseams and this term may be taken to mean annular seamslwhich are formed by pulling the material about a small hole in one ofthe sheets through the superimposed larger hole in the other of thesheets and securing the pulled through material to said last sheet. Therelative separating movement of the two sheets under inflation and theconsequent shaping or formation of the body into tufts etc., iscontrolled by positioning these annular self-seams at a plurality ofpredetermined positions in the pneumatic mattress cushion.

In some instances, as will hereinafter be described, holes in the sheetsof material are oblong or of other shapes than circular and may beVherein termed elongated self-seams. In either event registering holesare punched through both sheets, the holes in the lower sheets beingsomewhat smaller than those in the upper sheet. If the holes arecircular, they register concentric; whereas if they are of other shapes,they will register on their major axes. In either case the apertureformed should for best effectiveness be of material size and larger thanwould be required if no other function than that of separation-controlwere intended. However, the connected points have another very importantfunction which will also presently be described. With this in' view, itis preferable that the holes be not less than two inches in anydimension.

This method of forming the entire body of a pneumatic mattress cushionby lapping the edges of a multiplicity of registering aperturesdistributed over its entire surface is believed to be novel in this artbecause it not only dispenses with ties, reeds, stays, or tubesheretofore commonly used for controlling distention, but it also resultsin the formation of an entire body which possesses new and importantfeatures not obtainable in the same degree or with the same simplicityby similar devices of the prior art.

The pneumatic cushion or core of the mattress when inflated assumes theshape illustrated in Figure 2. The connected points 34 form acornparatively large elastic wall opening through the body, and theseopenings become in effect a cell within the inflated body, each cellbeing subjected to atmospheric pressure. These cells have sides whichconverge to a more or less constricted middle, to some extent resemblingan hour-glass, and these cells have an important function in producingflexibility and yet stability and comfort, as will presently bedescribed.

It is obvious that the separation of the upper and lower sheets is inproportion to the distance between the connected points 34, and thatsaid sheets will have their greatest separation at the point which isfarthest away from any of the connected points 34.

The exceptional flexibility afforded by this method of constructionenables me to shape me cushion both as to its thickness and to thesurface contours thereof. This is taken care of entirely by spacing ofthe connected points relative to each other. This method has a distinctadvantage over prior methods for producing surface contours by employinginterior stays or inserts of various shapes and lengths.

It can be seen by referring to Figure 1 that small parallelograms areformed in the surface of the pneumatic core consisting of depressedchannels or troughs 35 extending between adjacent connected points 34;the midportions of these parallelograms are rounded upwardly and formpeaks or tufts 3l.

In the embodiment shown in Figures 1 to 4, the connected points adjacentto the marginal edges of the cushion are spaced farther apart from saidmarginal edges than they are from each other. This produces a slightlyhigher and slightly firmer edge 38, which is often desirable in largecushions of this type.

In the embodiment shown in Figures 1 to 4, the pneumatic cushion or coreof the mattress is provided with an upper pad 3l, which may be formed ofcotton, kapok, or any other material desired, and a lower pad 40 whichmay be identical with the pad 39. A casing 4I, which may be made ofticking or any other material desired, completely encloses the pneumaticcore and the pads.

The casing may be provided with a zipper 42, which may open along oneedge and along each end for a short distance, as shown in Figure 12.Whenever it becomes necessary, the zipper` 42 may be opened, and eitherone or both sheets of the padding and/or the core may be renoved forcleaning or dusting, and either or both of the pads may be replaced withnew ones, after which the casing may be again closed.

The pneumatic insert or core is provided with a tube 43 having a valve44 thereon through which the cushion may be inflated.

When building cushions of very light weight, for example, to be used inairplanes where light weight is necessary or important, I may use verythin upper and lower sheets of rubber and reinforce the bonds betweenthe sheets in the manner shown in Figures 7, 8, and 10.

The lower sheet 45 may have holes 46 therein which are smaller than theholes 33 above described in connection with the thicker material.superimposed on this sheet is an upper sheet 41 having holes 48 thereinwhich are concentric with the holes 46. An annular reinforcing ring 49is adhered to the upper surface of the sheet 41 with its hole coincidingwith the hole 48, as shown in Figure 7. The edges of the sheet 45 aboutthe hole 46, which project inwardly beyond the edges of the hole 48, arepulled through the hole 48 and lapped over the reinforcing ring 49,thereby avoiding sharp creases and danger of weakening at the point ofbending, and said edges are adhered both to the ring 49 and to the uppersheet 41 immdiately thereabout. This construction provides a very strongjoint between the sheets.

` Figure 9 is a fragmentary view which illustrates the shape assumed bythe reinforced connected points 46.

When the weight of the user falls first on the points of the high tufts(as distinguished from falling first on a plane surface or on parallel,unbroken ridges present in air mattresses of the prior art), the tuftshaving free space al1 around them, have a high degree of elasticcompressibility and lateral expansion. They therefore yield easily tothe weight of the user and conform to the curves of his body. This maybe seen in Figure 4.

As the tufts flatten toward the lower, firmer, surrounding ridges, theresistance to vertical compression and lateral expansion isprogressively increased. This gives the desired combination of initialsoftness and final stability. In the progressive resistance justdescribed, the hourglass or double conoidal shape of the convergingsides of the apertures play an important part even beyond the pointwhere they function in common with the sloping walls of the tufts.

The body of the user, when itflnally comes to a "bearing is supported inpart by the partially flattened tufts and partially by the firmer ridgeswhich now tend to hold the tufts from lateral movement. This preventsinstability, rolling and curling. The elasticity of the confined airisnow also increased by the remaining tendency of the walls of thehour-glass" connected points to collapse upon themselves, or to expand,as the movements of the user cause increases or reductions of thesurface' pressures.

An additional important function of the hourglass connected points is toprovide ventilation through and over the surface of the rubber body,thereby avoiding perspiration. The hour-glass shape of the aperturesassists materially in performing this function, as its very shapefacilitates a pumping action under the movements of the user.Furthermore, this shape lends a vertical stability to the hollow cushionwhich is not present in straight, stiller walls of a tubular or otherform of inserted stay which is liable to bend under vertical pressurebesides being less yielding to lateral air-pressure.

Where cushions of this type are to be used for persons of light weight,or for hospital use, I further increase the flexibility and form-fittingsoftness of the article by using a limited number of holes of oblong orelongated oval shape in combination with the circular holes abovedescribed.

'I'his modification is shown in Figure 18 wherein the hour-glass holes34 are positioned the same as usual relative to the outer edges of themattress, and where the oblong or oval holes 50 are at or toward themiddle or main weight-bearing surface of the mattress or cushion.

This combination of circular and elongated apertures produces a mattressor cushion having a relatively soft, yielding center with a relativelyfirm surrounding area. It avoidsthe tendency to roll that the elongatedholes `would have if used alone, and in parallel arrangement.

A further modification shown in Figure 19 contemplates theprovision ofutmost stability, softnessv and comfort, for example in mattresses forambulances, hospital stretchers, operating tables, etc.

In this arrangement the used throughout the mattress and the apertures5| along one end of the mattress are inclined at an angle ofsubstantially 45-degrees with the longitudinal axis of the mattress. Thesecond row of elongated or oval apertures 52 are inclined at theopposite angle of l5-degrees with the longitudinal axis of the mattress.Throughout the mattress the rows of angular apertures are alternated.This l5-degree arrangement has a definite and important effect on thestability of the ,mattress without materially reducing the initialsoftness and form-fitting features above described; it produces aninflated body which has far less tendency to lateral ing than when theelongated apertures are placed with their axes parallel im thelongitudinal or the oblong apertures are lateral axis of' the mattress.

bedstead or frame, each Referring now to Figures 13 to 17, inclusive, afurther modification is shown in which the mattress is made in aplurality of sections 10, H and 12. These sections are all independentlyinflatable and defiatable. This form of the invention is particularlyuseful in connection with operating tables and certain special forms ofbeds for invalids, particularly in cases where certain parts of thepatients body, such as the dorsal arch, require special support orelevation. Each section is provided with ated with its neighbor, andcollectively the sections form one continuous cushion.

Figure 13 shows the separate sections 10, 1I and 'I2 as used on anadjustable bedstead or frame. The separations between the sectionscoincide with the pivotal or other joints of the section being attachedeffi.

to its supporting frame section by means of straps which are secured tothe center of each inflated section to permit blankets or sheets to betucked between the straps and under the. surface of the section. Thestrap on section is designated by the numeral 14; the one on section 1|by the numeral 15; and the one on section 12 is designated by thenumeral 16.

The section 10 has a pneumatic core 11 with a top pad 18 and a bottompad 19 enclosed in a casing 80. A valve 8| is provided for infiating ordefiating the core 11.

The section 1|, which is also shown in the exploded view Figure 15,includes a pneumatic core 82 having an upper pad 83 and a lower pad 84,said core and said pads being enclosed in a casing 85 which is providedwith straps 15 for securing it to the sub-frame 13a, as hereinbeforedescribed The casing may be provided with any desired form of closure,but in the arrangement illustrated, a zipper 86 is provided for qluicklyopening and closing the casing. The core 82 is provided with a valve 81through which it may be inflated or deflated.

The section 12 is likewise provided with a pneumatic core 88, with upperand lower pads 89 and 98 enclosed in a casing 9|, and inflatable anddeiiatable vvia the valve 92.

The section 13a. and/or the section 13h may be moved independently ofthe section I3 for the comfort of the patient or to place certain partsof his body in preferred positions.

The sub-frame 13 may be placed on a bed 93, for example, and in caseswhere the patients spine needs special support the middle section 1| maybe inflated to a level higher than the level of the surfaces of thesections 19 and 12.

Where the cores 11, 82 and 88 are constructed in the manner hereinbeforedescribed, these sections, when subjected to the weight of a body 94,assume -a form approximate to that shown in Figure 16.

A further modification contemplates the provision of a separatelyinflatable support for the sections. For example, referring to Figure16, the support 95 can be independently inflatable through the bag valve96. This would place at the disposal of the nurse or attendant an evengreater combination of arrangements for the patients comfort because notonly can the attendant vary the thickness of the sections 10, 1| and 12,independently of each other, but can also vary the thickness of thepneumatic supporting members, such as 95. For example, suppose it weredesired that some one of the sections 10, 1| or 12 be higher than theothers and at the same time softer than the others, that section couldbe deiiated to the desired degree of softness and its height could betaken care of by increasing the inflation of the pneumatic supportingmember 95.

In Figure 11 is shown a modification of the arrangement shown in Figure6, wherein an extra reinforcing grommet 98 is applied over the joint 34and adhered to both the walls 30 and 3|. This reinforcing member assumesthe position shown in Figure 11.

Although I have herein shown and described, by way of example, amethodof constructing pneumatic cores for mattresses and severalmodiiications thereof, it is obvious that many changes may be made inthe arrangement shown without departing from the spirit of the inventionas set forth in the annexed claims.

What is claimed is:

1. The method of making a pneumatic mattress which includes, theformation of a plurality of spaced holes of predetermined diameters inone sheet of uncured rubber or the like, the formation of a plurality ofholes of the same spacing in a second sheet of uncured rubber or thelike, said last holes being larger in diameter than said first holes,superimposing said second sheet on said first sheet with said holesmatching concentrically, pulling the material about the edges of saidfirst holes through said second holes and adhering the pulled-throughmaterial to said second sheet about the peripheries of said secondholes, adhering the edges of said sheets together in overlappingrelation, and the final step of vulcanizing said mattress.

2. The method of forming a tufted pneumatic mattress which includes theformation in one sheet of uncured rubber a plurality of holes ofpredetermined diameters spaced apart from each other in accordance withthe desired spacing of the tufts, the formation of a plurality of holesof the same spacingvin a second sheet of uncured rubber, said last holesbeing larger in diameter than said first holes, superimposing saidsecond sheet on said first sheet with said holes matchingconcentrically, cleaning the surface of said second sheet in annularzones surrounding said second holes, pulling the material about theedges of said first holes through the overlying second holes andadhering the pulled-through material to said second sheet within saidzones, cleaning the edges of said second sheet along zones adjacent tothe edges thereof, adhering the edges of said first sheet to the edgesof said second sheet in overlapping relation, and the final step ofvulcanizing said mattress.

3. The method of making a tufted pneumatic mattress which includes theformation in one sheet of uncured rubber, of a plurality of holes ofpredetermined diameters, and of predetermined spacing in accordance withthe desired -positions of the tufts, the formation of a second pluralityof holes of the same spacing but larger in diameter than said firstholes in a second sheet of uncured rubber, positioning said second sheeton said first sheet with said holes matching concentrically, therebyleaving within said second holes uncovered annular areas about saidfirst holes, adhering a plurality of reinforcing rings to said secondsheet, said reinforcing rings having holesthereinof substantially thesame diameter as said second holes, pulling each of said .uncoveredareas about said first holes through both the overlying hole in saidsecond sheet and the holeV -in its reinforcing ring and adhering thematerial of these uncovered areas to the outer surfaces of saidreinforcing rings, adhering the edges of said sheets together inoverlapping relation, and the final step of vulcanizing said mattress.

4. The method of forming hollowtufts in pneumatic mattresses whichconsists of forming aligned holes in the sheets of rubber or the like ofwhich said mattress is formed, one aligned hole being slightly larger indiameter than the other, the step of pulling the edges of the smallerhole through the larger hole and adhering said edges 'to the materialimmediately about the larger hole, and the step of vulcanizing saidsheets together along the area which is adhered, whereby when saidmattress is iniiated the vulv canized joint is positioned substantiallymidway vwith respect to the axes of tress which includes the formationboth of a plurality of spaced round holes of predetermined diameters andelongated holes in one sheet of uncured rubber or the like, theformation of holes of both kinds and of the same spacing in a secondsheet of uncured rubber or the like, said last holes being larger thansaid rst holes, superimposing said second sheet on said rst sheet withsaid round holes matching concentrically and said elongated holesmatching axially, pulling the material about the edges of the holes insaid iirst sheet through the holes in said second sheet and adheringsaid pulled-through material to said second sheet adjacent tol theoutline of the holes therein, adhering the edges of said sheets togetherin overlapping relation, securing a valve stem thereto, and the nal stepo vulcanizing said mattress.

6. 'I'he method of making a pneumatic mattress which includes theformation of a plurality of elongated holes in rows in one sheet ofuncured rubber or the like, the axes of said holes being substantiallyparallel, the` formation of other rows of elongated holes interspersedbetween said tlrst rows and having their axes substantially parallel toeach other and angular holes, the forming of holes the same spacing in aot both kinds and of second sheet of uncured said rst elongated rubberor the like, said last holes being larger than said ilrst holes,superimposing said second sheet on said ilrst sheet with the holes insaid sheets matching axially, pulling the material about the edges ofthe holes in ,said rst sheet through the holes in said second sheet andadhering said pulled-through material to said second sheet adjacent tothe outlines of the holes therein, adhering the edges of said sheetstogether, and the iinal step of vulcanizing the mattress.

7. The method of making a pneumatic mattress which includes theformation in one sheet A of uncured rubber or the like, of a pluralityof holes of predetermined diameters and arrayed therein in accordancewith a predetermined pattern, the formation oi a pluralityoi slightlylarger holes of the same spacing in a second sheet of uncured rubber orthe like, superimposing said second sheet on said rst sheet with saidholes matching concentrically, pulling the material about the edgesof'said ilrst holes through said second holes and adhering the materialto said second sheet about the peripheries of said second holes,adhering the edges of said sheets together `to forma closure, and theiinal step of vulcanizing said mattress.

GEORGE H. PERRY.

